Reusable modular system for making battery packs in series and parallel configurations

Abstract

A battery pack system convertible among a series configuration, a parallel configuration, or both. The battery pack system includes a base component case having a housing configured to receive therein multiple batteries, and an expansion component case or a cap secured to the base component by a twist-and-lock feature. The battery pack system includes a positive conductor and a negative conductor running along an elongated interior of the base component case, and an insert composed of a dielectric and having a positive terminal and a negative terminal. The insert is configured to be inserted between adjacent batteries such that the positive terminal electrically connects to the positive conductor and the negative terminal electrically connects to the negative conductor to form a parallel-electrical connection between an adjacent battery pair, and such that, without the insert, an adjacent battery pair forms a series-electrical connection therebetween.

1 . A battery pack system convertible among a series configuration, a parallel configuration, or both, the battery pack system comprising:
 a base component case having a housing configured to receive therein a plurality of batteries;   an expansion component case or a cap secured to the base component by a twist-and-lock feature;   a positive conductor and a negative conductor running along an elongated interior of the base component case;   an insert composed of a dielectric and having a positive terminal and a negative terminal, wherein the insert is configured to be inserted between adjacent ones of the plurality of batteries such that the positive terminal electrically connects to the positive conductor and the negative terminal electrically connects to the negative conductor to form a parallel-electrical connection between the adjacent ones of the plurality of batteries, and such that without the insert the adjacent ones of the plurality of batteries form a series-electrical connection therebetween.   
     
     
         2 . The battery pack system of  claim 1 , wherein the expansion component case or the cap includes a positive conductor and a negative conductor running along an elongated interior of the base component case, wherein the positive conductor of the expansion component case or the cap mechanically and electrically connects to the positive conductor of the base component case when the twist-and-lock feature locks the base component case to the expansion component case or the cap, and wherein the negative conductor of the expansion component case or the cap mechanically and electrically connects to the negative conductor of the base component case when the twist-and-lock feature is disengaged to release the base component case from the expansion component case or the cap. 
     
     
         3 . The battery pack system of  claim 1 , further comprising an o-ring between the base component case and the expansion component case or the cap to form a waterproof seal therebetween. 
     
     
         4 . The battery pack system of  claim 3 , wherein the o-ring is seated around an exposed end of the base component case. 
     
     
         5 . The battery pack system of  claim 1 , wherein a length along the elongated interior of the housing is dimensioned to be shorter than a total number of the plurality of batteries that can be inserted into the housing. 
     
     
         6 . The battery pack system of  claim 2 , wherein the housing has an opening from which the positive conductor and the negative conductor are exposed, the battery pack system further comprising a layer of silicone below respective exposed surfaces of the positive conductor and the negative conductor to ensure a continuous and reliable electrical connection interface between (a) the positive conductor and the negative conductor of the base component case and (b) the positive conductor and the negative conductor of the expansion component case or the cap during heavy vibration. 
     
     
         7 . The battery pack system of  claim 2 , further comprising a plurality of magnets along an exterior of the housing and a magnet along an exterior of the expansion component case or the cap such that all of the magnets lie on the same plane to contribute to a continuous and reliable electrical connection interface between the base component case and the expansion component case or the cap. 
     
     
         8 . The battery pack system of  claim 1 , wherein the positive terminal includes a battery mating surface that contacts a positive terminal of one of the batteries and the negative terminal includes a battery mating surface that contacts a negative terminal of an other one of the batteries. 
     
     
         9 . The battery pack system of  claim 1 , wherein the positive terminal of the insert includes a first spring portion that is spring-biased against the positive conductor responsive to the insert being positioned inside the housing, and the negative terminal of the insert includes a second spring portion that is spring-biased against the negative conductor responsive to the insert being positioned inside the housing. 
     
     
         10 . The battery pack system of  claim 1 , in combination with a tool used to insert and remove the insert relative to the housing to convert the battery pack system between a series-electrical configuration and a parallel-electrical configuration, the tool comprising:
 an elongated handle;   an insert coupling mechanism at an end of the elongated handle, the insert coupling mechanism including a locking member that locks the mechanism to the insert by a rotational twist of the elongated handle relative to the mechanism.   
     
     
         11 . The battery pack system of  claim 10 , the insert having a plurality of notches each having a different width from one another, and the insert coupling mechanism having a corresponding plurality of protrusions such that the notches of the insert can be received by the protrusions of the handle in one orientation only. 
     
     
         12 . The battery pack system of  claim 10 , the tool further comprising a detent that is configured to press against the locking member to cause it to be urged outwardly in a radial direction away from the handle, thereby creating a bias force against one of the plurality of notches sufficient to hold the insert against the tool even when both are held upside down relative to earth. 
     
     
         13 . The battery pack system of  claim 10 , the insert including a plurality of registration members, the housing including a plurality of corresponding grooves, wherein the registration members of the insert ensures that a major surface of the insert maintains an orthogonal orientation relative to a bottom of the housing as the insert is introduced therein by pushing the tool and the insert until the insert is seated against the bottom of the housing or against a top of one of the plurality of batteries already present in the housing. 
     
     
         14 . The battery pack system of  claim 1 , wherein the plurality of batteries can be connected together according to at least one series configuration and at least one parallel configuration or at least two different series configurations and at least two different parallel configurations or at least three different series configurations and at least three different parallel configurations. 
     
     
         15 . The battery pack system of  claim 1 , wherein the housing is composed of a nylon or a carbon fiber. 
     
     
         16 . A battery pack system convertible among a series configuration, a parallel configuration, or both, the battery pack system comprising:
 a housing having an open end and a lid configured for the series configuration or the parallel configuration or both;   a plurality of exposed conductor spring terminals extending beyond the open end of the housing such that when the lid is secured onto the housing, the terminals become spring-biased to create a constant tension against corresponding conductors formed on an underside of the lid, wherein a pattern of the conductors determines whether the lid is configured for the series configuration, for the parallel configuration, or for both.   
     
     
         17 . The battery pack system of  claim 16 , wherein the lid is configured for the parallel configuration, in which the pattern of the conductors includes a first conductor pattern having a first section that electrically connects to two of the exposed conductor spring terminals and a pad that electrically connects to a third of the exposed conductor spring terminals, the pattern of conductors including a second conductor pattern having a plurality of first pads that connect to corresponding terminals of corresponding batteries present in the housing and a second pad that electrically connects to one of the exposed conductor spring terminals. 
     
     
         18 . The battery pack system of  claim 16 , wherein the lid is configured for the series configuration, in which the pattern of conductors includes a first pad that electrically connects to a first of the exposed conductor spring terminals, a second pad that electrically connects to a second of the exposed conductor spring terminals, and a third pad that electrically connects to a third of the exposed conductor spring terminals, where two of the first, second, and third pads have an identical form. 
     
     
         19 . The battery pack system of  claim 16 , wherein the lid is configured for both the series and the parallel configuration such that at least a first pattern of conductors connects at least two batteries inside the housing in series and at least a second pattern of conductors connects at least two batteries or battery assemblies inside the housing in parallel. 
     
     
         20 . The battery pack system of  claim 1  in which at least two of the plurality of batteries are connected together in series inside the housing and at least two others of the plurality of batteries are connected together in parallel inside the housing.